Got a pickup...back on track again

[clm2112]

Well, back from the first test flight after months of work. It is throwing an intermittent check engine light, which I have to scan tomorrow (probably the diverter valve or O2 sensor, only throws the code after going into closed loop and coasting along, goes out when engine is accelerating). I'll hook the scan tool up to it in the morning and see what's up during the drive to work.

It is driving well enough to go to work in it tomorrow. (Headers sound pretty good, the exhaust note is heavily muffled by the huge stock can. Perhaps a new muffler is in order

Meanwhile, back to working on the house.

[ga93sle]

My dad and brother both have F-150s with the dual tanks, and neither of them work right. One of them quit when the truck was almost new, was never done anything with, 10 years later it decided to start working again and started pumping 10 year old gas back through the engine... turned into a big mess lol.

[clm2112]

Seems like a fairly common problem for dual tank F-Series pickups. There was even a recall on the setup. The way it works, there is a high pressure check valve and a shuttle valve on each fuel pump assembly inside the fuel tanks. When a pump is running, the shuttle valve is supposed to open to give the returning fuel from the rail a place to dump into the same fuel tank it was pumped out of. The check valve is suppose to prevent the fuel from flowing backwards through the pump that is turned off. If any of the four valves stick or fail, all sorts of goofy stuff starts happening.

I'm glad I ditched the tank. I don't really need it and the fuel system becomes more reliable without relying on those four valves working correctly. I've got a spare pump now if I need it later, though, I think I would rather use a GM style in-tank pump and skips the FDM valves completely. I know the GM pump setup works.

[ga93sle]

On the one truck that we fixed, we pulled the box off cause we were told that it was easier to work on that way, and we bypassed the front tank like you did, but we left the tank. Idk that the other truck has even been touched...

[clm2112]

Well, first trip to work ended on a flatbed.

Truck drove to work fine, no problems. Lunch time, I got a call from the Realtor that they wanted to show the house in the afternoon. Drove the truck home, picked up a house key, dropped the key at the realtors, then headed back to work. When I went to get on the interstate, the truck wouldn't accelerate. Engine racing, but the truck just coasting along. Couple of pops and bangs and the truck took off. When I got up to 70mph, truck wouldn't hold 4th gear.

Managed to make it back to work, check the tranny fluid, looked around for anything obvious, then started calling transmission shops. 1st choice couldn't even look at the truck until Wed. 2nd choice came at 5:00pm with a flatbed. Drove the truck up onto it and away they went. (I'll hear later this morning what they think is wrong with the transmission.)

[gonzo4191]

im guessing you for the e4od??

[00Beast]

That sucks Curt...

[clm2112]

Well, the good news, according to the transmission shop, is that the transmission is OK. They are doing the fluid & filter change on it, along with the front driveshaft U-Joint (not that it will get to use 4WD anytime soon with mismatched tire sizes.) The issue with the shifting resulted from the engine code being thrown... which goes straight back to the missing diverter valve from the smog pump. It was bucking and not holding gears because the extra air from the smog pump was hitting the O2 sensor and creating a false lean condition in closed loop. As long as the engine is cold, it runs fine. Warm it up and it starts acting like the transmission is toast.

So, I should get the truck back today, I have a junkyard diverter valve to install (not the exact valve called for, but at least in the same family of valves.. 9F491) and the basic diagram on how the missing valve is supposed to connect.

I also ordered a new Y-Pipe & single cat to replace the stock dual cat as well as the missing check valve for the diverter to cat hose that needs to go in too. I got my work cut out for me tonight getting the bulk of the diverter plumbing put back to what it should be. Y-Pipe & Cat might get here by the weekend, which will make the entire system function the way Ford intended it to work. (Hope that get's rid of the last engine code.)

I'll have to hold off on a new muffler for a few weeks. Probably a MagnaFlow/Dynomax or Flowmaster. I'm holding off on ordering it until I have the Y-Pipe & cat in hand. I've read that the pipe I ordered is actually 2.5" from the header flanges, through the cat, and steps down to 2.25" at the very end to mate up with Ford's stock 2.25" muffler pipes. If that is true, I'll lop the reduction off and run 2.5" though the muffler all the way to the exhaust tip. If it isn't true, then I'll just use the stock 2.25" muffler and pipe.

[myfirstbonnie]

It is always good news to hear a minor repair instead of the expensive ones. A lot more work for you, but your wallet will still have enough for dinner.

[clm2112]

It is always good news to hear a minor repair instead of the expensive ones. A lot more work for you, but your wallet will still have enough for dinner.

Yes, the repair bill went from an anticipated $1500 for another 4R70W to $300 for all the work and the towing to get it there. They did fluids in the transmission/transfer case, both axles, and replaced all four driveshaft U joints. Heading out in about and hour and a half to pay up and pick it up. When I get home tonight, it will be another hour or two under the hood with the diverter valve. Everything is already laid out on the kitchen table. Just a matter of climbing up there and getting it done.

If this was all it took to fix the problem, then I'll just chalk this one up to experience. I knew months ago that I should address the missing diverter valve. I just never figured on just how bad the engine would behave with it getting the flow of the AIR pump into the exhaust ports all the time. (transmission shop is also disconnecting the air pump hose at the check valve for me, just so it doesn't code out on the way back to the house.)

[00Beast]

Good to hear Curt! At least it wasn't too expensive...

[clm2112]

Truck is back at house. Made the 15 mile trip home with the AIR pump disconnected and threw not a single code. As soon as the motor cools off, I'm going to hook a diverter valve up to it and recheck the ignition base timing.

Flight testing resumes again tomorrow morning

Edit: Diverter valve is hooked up now, threw a code on a short test drive. Came back and reversed the vac lines on the solenoids (I may have the AIR B and AIR D solenoids reversed on the valve cover bracket.) Another test drive, no codes this time. When I have daylight to work with, I'll trace the two solenoid connectors back and make sure of which is wired as the Bypass and which is the Diverter. Tomorrows test drive should be interesting.

One thing, the Bonneville electric fan will cool the motor off pretty quickly. It just doesn't come on soon enough (dash gauge is almost at the over-temp mark when it turns on). Looks like I need a lower temp on/off switch on the intake manifold to turn it on sooner. I also need to move it the relay to a circuit that is only powered when the key is on. It's a little disconcerting to shut the vehicle off and have the fan still running. More poking around in the wiring harness to find a better circuit.

[clm2112]

Start of another day in what is perhaps the longest thread on record (post whorage anyone :wink )

USP & FedEx showed up yesterday. Bringing a stainless Y pipe, cat, and muffler. Still need a length of 2.5" stainless pipe along with a 90 degree elbow to complete the entire exhaust from headers to tip. Called around local shops, nobody has it, so it looks like Monday to get the pipe and whack the exhaust.

Meanwhile, I have a stack of lumber in the kitchen (some for the house, some for the truck) to start constructing the deck on the bed.

I got really motivated the night before last, and welded together most of the front bumper pieces. Going out this morning to finish the two braces and paint it. (pictures later)

Truck ran well the past two days. Driving it got better after getting the plates on the top of the bumper installed. (they must really alter the airflow around the front of the truck, it doesn't wander around on the interstate now.)

[clm2112]

Welded up bumper:



Decking the flatbed:

[00Beast]

Looks good!!

When are the other two tires going on?!

[clm2112]

Soon, waiting for the severance check, then I'll play musical tires (the two on the truck still have a lot of tread left, so I'll save them for the Galaxie.)

[00Beast]

Gotcha.

[clm2112]

I gave in.. bought the two tires for the back end today

Tomorrow I have to reprogram the PSOM function to correct the speedometer.

*dang* near sold the front bumper off the truck. Fellow mounting the tires has a lifted 90's Bronco. Asked me if I would be interested in making another bumper.

[Jrs3800]

Curt I am liking that truck more and more...lol

[myfirstbonnie]

Definately going to be a good hauler.